US5964911A - Process for making an abrasive composition - Google Patents

Process for making an abrasive composition Download PDF

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Publication number
US5964911A
US5964911A US09/139,475 US13947598A US5964911A US 5964911 A US5964911 A US 5964911A US 13947598 A US13947598 A US 13947598A US 5964911 A US5964911 A US 5964911A
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Prior art keywords
glass
weight percent
recited
electric arc
arc furnace
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US09/139,475
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James Morano
Gerald P. Balcar
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Dynamic Abrasives LLC
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Individual
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Priority claimed from US09/123,741 external-priority patent/US6057257A/en
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Priority to US09/139,475 priority Critical patent/US5964911A/en
Assigned to GREENWALD, HOWARD J. reassignment GREENWALD, HOWARD J. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BALCAR, GERALD P., MORANO, JAMES
Priority to PCT/US1999/012111 priority patent/WO2000006509A1/fr
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Publication of US5964911A publication Critical patent/US5964911A/en
Assigned to MORANO, JAMES reassignment MORANO, JAMES ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ENVIRONMENTAL SCIENCE TECHNOLOGY, INC.
Assigned to MORPAT TRUST UTD 10/15/2003, THE reassignment MORPAT TRUST UTD 10/15/2003, THE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MORANO, JAMES
Assigned to INTERNATIONAL MELTING & MANUFACTURING, LLC reassignment INTERNATIONAL MELTING & MANUFACTURING, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GREENWALD, HOWARD J.
Assigned to MORANO, JAMES reassignment MORANO, JAMES ASSIGNMENT OF EIGHTY-FIVE PERCENT (85%) INTEREST IN PATENTS Assignors: MORPAT TRUST
Assigned to DYNAMIC ABRASIVES LLC reassignment DYNAMIC ABRASIVES LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: INTERNATIONAL MELTING & MANUFACTURING, LLC
Assigned to INTERNATIONAL MELTING & MANUFACTURING, LLC reassignment INTERNATIONAL MELTING & MANUFACTURING, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MORANO, JAMES, MORANO, JAMES AS CO-TRUSTEE OF THE MORPAT TRUST
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1409—Abrasive particles per se
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B19/00—Other methods of shaping glass
    • C03B19/10—Forming beads
    • C03B19/1005—Forming solid beads
    • C03B19/1045—Forming solid beads by bringing hot glass in contact with a liquid, e.g. shattering
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
    • C03C1/002—Use of waste materials, e.g. slags
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C12/00—Powdered glass; Bead compositions
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    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/138—Waste materials; Refuse; Residues from metallurgical processes, e.g. slag, furnace dust, galvanic waste
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Definitions

  • a process for making an effective, durable, and environmentally safe abrasive composition in which a mixture of electric arc furnace dust and silica is melted, quenched, and crushed.
  • EAF dust In the electric arc furnace (or "EAF") process used to make various grades of steel, a considerable amount of dust, known as “EAF dust,” is generated. In addition to containing iron oxides derived from the steel making process, this dust also contains significant amounts of toxic substances, such as compounds of lead, cadmium, chromium, and other heavy metals. These toxic substances are contained in the dust in a potentially soluble condition, and the EAF dust thus has to be treated as a toxic material for waste disposal purposes. As is disclosed at lines 13-15 of column 1 of U.S. Pat. No. 5,278,111 of Scott W. Frame, "EAF dust is classified as a hazardous waste by the Environmental Protection Agency and is designated the identification K061.”
  • the EAF dust may be fixated and/or stabilized in compositions containing lime, Portland cement, or class "C" fly ash, which are alkaline in nature but that, when such fixated and/or stabilized compositions are subjected to acid rain, the pH levels within the compositions will decrease, thereby allowing many of the heavy metals in the EAF dust (such as lead, nickel, and chromium, to be re-solubilized in water (see lines 15-25 of column 2).
  • the heavy metals in the EAF dust such as lead, nickel, and chromium
  • the vitrification process is energy intensive and relatively expensive, and it generally produces a product whose only commercial utility is for use in an landfill. It would be desirable to be able to make a useful, salable product from the vitrified EAF dust such as, e.g., a hard abrasive.
  • U.S. Pat. No. 5,009,511 of Leonard S. Sarko et al. discloses a process which, according to the patentees, produces a finished product which may be used " . . . to make grinding wheels, stones, sandpaper, shot blast material, and other abrasives . . . " (see column 17, lines 4-7).
  • the process of this patent " . . . comprises three key steps (1) oxidation-reduction reaction, (2) blending with silicate, and (3) vitrification.
  • the oxidation-reduction reaction is necessary in order to place the inorganic hazardous waste components into a form for chemical reaction.
  • the blending step is necessary to intimately mix the oxidation-reduction product with the silicates so as to ensure a complete reaction of the inorganic hazardous waste components with the silicates.
  • the vitrification step is necessary in order to effect the chemical reaction which will chemically bind the inorganic hazardous waste components to the silicate matrix.
  • Balcar et al. patents teach that one cannot make a hard abrasive from vitrified oxide-containing material, such as vitrified EAF dust.
  • vitrified oxide-containing material such as vitrified EAF dust.
  • Balcar et al. discuss U.S. Pat. No. 5,009,511 of Sarko et al. and state that "The Sarko et al. reference teaches a mobile system for fixing a hazardous waste in a silicate matrix . . .
  • a material might have good hardness and fracture toughness properties does not necessarily mean that it will be a good abrasive.
  • Diamond is harder than CBN, and more effective on carbides, but less effective on steels . . . Aluminum oxide is more effective on most steels and less so on nonferrous metals and nonmetallic substances than is silicon carbide.
  • the best explanation of the problems of diamond an silicon carbide on steel is that there is a chemical reaction between the abrasive and the steels which in effect ⁇ melts ⁇ the abrasive and causes excess wear.”
  • a process for making an abrasive composition in which electric arc furnace dust is mixed with silica to prepare a thermally crystallizable mixture.
  • the thermally crystallizable mixture used in the process is melted by subjecting it to a temperature of from about 2,300 to about 2,900 degrees Fahrenheit.
  • the glass melt is then quenched, and the quenched glass is then crushed.
  • FIG. 1 is a flow diagram of a preferred process of the invention.
  • the first part of this specification will describe a preferred abrasive composition comprised of crystalline material.
  • the second part of this specification will describe a preferred process for making such abrasive composition.
  • composition of this invention preferably is comprised of both a glassy phase and crystalline phase. It generally contains from about 5 to about 80 percent of glass material, and from about 95 to about 20 percent of crystalline material.
  • the phases of the abrasive grains of the composition of this invention may be analyzed by X-ray diffraction analyses.
  • a Siemens D-500 Diffractometer (model number C72298-A223-B-9-POZ-228), manufactured by the Siemens Company of Germany) was used with copper K-alpha radiation and a diffracted beam graphite monochrometer; see, e.g., U.S. Pat. No. 5,157,015, the entire disclosure of which is hereby incorporated by reference into this specification.
  • the majority phase present in the surfaces of such grains will be determined.
  • analyses is conducted at a X-ray resolution of at least 5.0 percent, then it indicates that a crystalline phase is present in the surfaces of such grains as the majority phase.
  • the crystalline phase contains magnetite.
  • the abrasive grains of the composition of this invention are comprised of iron, silicon, calcium, and zinc, as identified by energy dispersive X-ray analysis (EDAX).
  • EDAX energy dispersive X-ray analysis
  • chromium is also detected by such EDAX analyses.
  • the crystalline phase contains magnetite (Fe 3 O 4 ), JCPDS 19-629. In another embodiment, the crystalline phase contained magnetite and elemental iron.
  • novel abrasive grains are substantially inhomogeneous, i.e., the composition of the core of the grains differs from the composition of the surface of the grains. Furthermore, it is also believed that the surface of such grains is inhomogeneous, when measured by EDAX at a scale of 100 microns ⁇ 100 microns (or smaller), varying from one surface site to another.
  • the crystals present in the abrasive grains are embedded within a glass matrix.
  • the abrasive composition of this invention is comprised of at least about 60 weight percent of ferrometasilicate, which has the formula FeSiO 3 .
  • iron(II) metasilicate has a molecular weight of 131.93, and a melting point of 1,146 degrees Centigrade.
  • This iron compound is well known in the art and is described, e.g., in U.S. Pat. Nos. 5,326,526, 4,604,140, 4,519,811, 4,205,392, 3,650,802, 3,616,041, and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • the abrasive composition contains from about 60 to about 85 weight percent of such ferrometasilicate. In another embodiment, the abrasive composition contains from about 80 to about 85 weight percent of ferrometasilicate.
  • the abrasive composition is also comprised of at least five weight percent of one or more spinels.
  • a normal spinel is a material with the formula AR 2 O 4 , wherein A is a divalent metal ion and R is a trivalent metal ion.
  • A is usually a divalent metal or mixture of divalent metals such as magnesium, ferrous ion, zinc, calcium, cadmium, cobalt, copper, nickel, strontium, barium, nickel, and manganese, and R is usually selected from the group consisting of ferric ion, aluminum, and chromium.
  • Typical spinels exist when A is zinc and R is iron, when A is magnesium and R is aluminum, when A is iron and R is aluminum, when A is cobalt and R is aluminum, when A is nickel and R is aluminum, when A is manganese and R is aluminum, and when A is zinc and R is aluminum. See, e.g., pages 64-66 of W. D. Kingery et al.'s "Introduction to Ceramics," Second Edition (John Wiley & Sons, New York, 1976).
  • the formula for these inverse spinels is R(AR)O 4 .
  • the abrasive composition of this invention contains from about 7 to about 25 weight percent of one or more spinels.
  • the abrasive composition of this invention contains at least 70 weight percent of its material in a crystalline structure, and at least 2 weight percent (and preferably at least five weight percent) of its material in an amorphous, vitreous structure. It s preferred that the abrasive composition contain at least about 80 percent of its material in a crystalline structure. In another embodiment, the abrasive composition contains at least 90 percent of its material in a crystalline structure.
  • the determination of the percent crystallinity in a material, and the percent glass may be determined by the well-known X-ray diffraction technique. See, e.g., John P. Sibilia's “A Guide to Materials Characterization and Chemical Analysis,” (VCH Publishers, Inc., New York, N.Y., 1988), at pages 115-133. Reference also may be had to an article by Ohlberg et al., "Determination of Percent Crystallinity by X-Ray Diffraction," American Ceramic Society, October, 1960, pages 170-171. One also may refer to U.S. Pat. Nos. 5,432,137, 5,358,631, 5,376,259, and the like, the entire disclosures of which are hereby incorporated by reference into this specification.
  • the ratio of material in the composition which is crystalline to that material which is glass be from about 8/1 to about 50/1.
  • the abrasive composition of this invention is preferably comprised of abrasive grains wherein at least about 60 weight percent of which have either the blocky and/or pyramidal (triangular) grain shape. In one preferred embodiment, at least about 70 weight percent of the abrasive particles are of the blocky and/or pyramidal shape. In one embodiment, an abrasive material which about 70 percent angular and 30 percent blocky became more angular in use.
  • the abrasive composition of this invention is substantially durable; it generates relatively little dust in use.
  • a test is conducted in which fifty pounds of abrasive are loaded into a 6.0 cubic foot Schmidt blasting pot (sold by the Schmidt Manufacturing Company of Houston, Texas) equipped with a feed valve and a number 6 nozzle. With this assembly, abrasive is blasted at 85 pounds per square inch onto four separate steel plates, each 6' ⁇ 8', two of which are coated with scale, one of which is coated with ISO level sea rust, and one of which is coated with a synthetic coating; the plates are located 20 inches away from the nozzle. During the test, photographs are taken to determine the extent of dustiness. The abrasive composition of this invention produces relatively little dust.
  • the abrasive composition of this invention has a Vickers fracture toughness, as measured by the indentation technique, of from about 0.9 to about 1.3 (and, more preferably, from about 0.94 to about 1.2) megaPascals.meters 0 .5.
  • Means for determining Vickers fracture toughness are well known and are described, e.g., in U.S. Pat. Nos. 5,769,176, 5,759,933, 5,658,837, 5,655,956, and the like; the disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • the abrasive composition of this invention has a Vickers hardness, tested with a 200 gram load and a 10 to 15 second loading time, of at least about 550 and, more preferably, at least about 650.
  • the Vickers hardness number is a number related to the applied load and the surface area of the permanent impression made by a square-based pyramidal diamond indentor having included face angles of 136 degrees. Means for determining Vickers hardness are well known to those skilled in the art and are described, e.g., in U.S. Pat. Nos.
  • the abrasive composition of this invention has a density of 2.8 to about 4.1 grams per cubic centimeter.
  • the abrasive composition of this invention is environmentally safe; it does not exceed the United States Environmental Protection Agency's Leaching Procedure regulatory limits.
  • the Environmental Protection Agency has published a test (at 40 Code of Federal Regulations [C.F.R.] 268.7[a]) for determining the leachability of hazardous substances in a material. This test is well known and is described, e.g., in U.S. Pat. Nos. 5,769,961, 5,766,303, 5,762,891, 5,754,002, 5,744,239, and the like; the disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • the abrasive composition of this invention exhibits superior speed of cleaning when used as a loose grain abrasive.
  • samples of the abrasive were blasted at 85 pounds per square inch with a number 6 (3/8") nozzle at 14 to 20 inches.
  • a 20-50 abrasive composition was tested. This composition had a particle size distribution such that at least about 80 percent of its particles passed through a 20 mesh screen (841 microns) but were retained on a 50 mesh screen (297 microns).
  • the performance was 3.97 square feet per minute.
  • level A scale the performance was 2.65 square feet per minute.
  • Level C Rust the performance was 6.56 square feet per minute.
  • Coated Steel the performance was 4.42 square feet per minute.
  • a 40-80 abrasive composition was tested. This composition had a particle size distribution such that at least about 80 percent of its particles passed through a 40 mesh screen (420 microns) but were retained on a 80 mesh screen (177 microns).
  • the performance was 5.1 square feet per minute.
  • level A scale the performance was 2.88 square feet per minute.
  • Level C Rust the performance was 4.88 square feet per minute.
  • Coated Steel the performance was 1.93 square feet per minute.
  • a 50-120 abrasive composition was tested. This composition had a particle size distribution such that at least about 80 percent of its particles were passed through a 50 mesh screen (297 microns) but were retained on a 120 mesh screen (125 microns).
  • the performance was 5.9 square feet per minute.
  • level A scale the performance was 3.83 square feet per minute.
  • Level C Rust the performance was 3.98 square feet per minute.
  • Coated Steel the performance was 3.8 square feet per minute.
  • a 80-200 abrasive composition was tested. This composition had a particle size distribution such that at least about 80 percent of its particles passed through a 80 mesh screen (177 microns) but were retained on a 200 mesh screen (74 microns).
  • the performance was 4.35 square feet per minute.
  • level A scale the performance was 2.16 square feet per minute.
  • Level C Rust the performance was 2.45 square feet per minute.
  • Coated Steel the performance was 2.85 square feet per minute.
  • the abrasive composition of this invention is preferably made from electric arc furnace dust.
  • Electric arc furnace dust also is sometimes referred to as "EAF dust,” “EAFD,” or "baghouse dust.”
  • Electric arc furnace dust is generally a mixture containing metal oxides that are collected by scrubbers, electrostatic precipitators, bag filters, or other known filtering systems in electric arc furnace (EAF) steel making facilities. It typically is composed mainly of oxides of iron, zinc, lead, tin, cadmium, chromium, manganese, nickel, copper, and molybdenum; but silica, lime, and alumina may also be present in the dust.
  • Electric arc furnace dust and means for its use and/or disposal, are extensively described in the patent literature. See, e.g., U.S. Pat. Nos. 5,738,683 (formation of briquettes from EAFD), 5,698,759 (process for combining EAFD and polyvinylchloride), 5,672,146 (low temperature vitrification of a mixture of EAFD, silica, and alumina), 5,667,553 (process for recovering metals from EAFD), 5,589,118 (process for recovering iron from EAFD), 5,557,031 (use of electric arc furnace by-products in concrete), 5,368,627 (plasma treatment of oxide containing dusts), 5,338,336 (gasification of EAFD to produce reduction gas and molten iron), 5,278,111 (EAFD as a raw material for brick), 5,245,122 (stabilization of EAFD by entrapping it within a cementitiously hardened product), 5,188,658 (process for recovering zinc from zinc-containing
  • the EAF dust used in the process of this invention have a particle size distribution such that at least about 70 weight percent of its particles are smaller than about 20 microns. In another embodiment, at least about 80 weight percent of the EAF dust particles are smaller than about 20 microns.
  • the EAF dust used in the process of this invention typically contains from about 35 to about 65 weight percent of at least one iron oxide compound and/or iron, and, more preferably, from about 45 to about 55 weight percent of iron oxide and/or iron.
  • it may contain black iron oxide, such as, e.g., ferrosferric oxide, ferroferric oxide, iron oxide, magnetic, black rouge, and the like.
  • black iron oxide such as, e.g., ferrosferric oxide, ferroferric oxide, iron oxide, magnetic, black rouge, and the like.
  • hematite also known as red iron ore, bloodstone, or iron oxide
  • it may contain the iron oxide identified as Chemical Abstracts number CAS 1309-37-1.
  • the EAF dust used in the process of this invention contain from about 0.1 to about 4.0 weight percent of one or more divalent metal oxides selected from the group consisting of cadmium oxide, lead oxide (such as, e.g., litharge), and mixtures thereof. In one embodiment, the EAF dust contains from about 0.5 to about 3.0 weight percent of lead oxide.
  • the EAF dust also preferably should contain from about 0.1 to about 3.0 weight percent of an oxide selected from the group consisting of aluminum oxide, chromium oxide, titanium oxide, and mixtures thereof.
  • the EAF dust used in the process of this invention preferably contains from about 0.05 to about 5 weight percent of at least one oxide of chromium, also known as "chromic oxide” and, preferably, from about 0.05 to about 0.2 percent of at least one oxide of chromium.
  • the chromic oxide may be chromium (III) oxide, chromia, chromium sesquioxide, green cinnabar, and the like.
  • the chromium molecules serve as crystallization sites for the spinels which form at the quench, thereby increasing the hardness of the abrasive formed.
  • the EAF dust used in the process of this invention can contain from about 10 to about 35 weight percent of zinc oxide, which is also known as "Chinese white” and “zinc white.” In one embodiment, no zinc oxide is present in the EAF dust. Without wishing to be bound to any particular theory, it is believed that the zinc might facilitate the formation of spinel structures in the abrasive.
  • the EAF dust used in the process of the invention should preferably contain from about 0.1 to about 3.0 weight percent of one or more oxides of manganese, and/or from about 0.1 to about 3.0 weight percent of one or more oxides of magnesium. It is believed that these oxides also contribute to the formation of the desired spinel structure which, in turn, contributes to the desired hardness and fracture toughness properties of the abrasive.
  • the EAF dust used in the process is obtained from Nucor Steel Company of Armorel, Arkansas as "Steel Mill Electric Arc Furnace Dust"
  • EAF dust is charged via line 12 to mixer 10.
  • from about 50 to about 85 weight percent of EAF dust (by total weight of material in mixer 10) is charged to mixer 10. It is preferred to charge from about 50 to about 75 weight percent of the EAF dust to mixer 10. In one embodiment, from about 60 to about 70 weight percent of such EAF dust is charged to mixer 10.
  • glass is charged via line 14 to mixer 10; in another embodiment, other sources of silica or silicates or charged via line 14.
  • the glass so charged be crushed to a particle size distribution such that at least about 70 percent of its particles have a maximum dimension smaller than about 1.0 centimeter. It is even more preferred that glass used be glass cullet.
  • soda lime glass cullet of mixed chips which is preferably obtained from residential glass recycling plants; soda lime glasses contain silica, sodium oxide, and calcium oxide.
  • Soda lime glass cullet material is well known and is commercially available; see, e.g., U.S. Pat. Nos. 5,731,367, 5,585,452, 5,563,232, 5,538,786, 5,468,432, 5,350,778, 5,028,569 (virgin soda lime glass cullet), 4,934,307, 4,541,842, and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • soda lime glass and/or soda lime glass cullet may additionally and/or alternatively use other glass compositions such as borosilicate glass, aluminosilicate glass, Vicor glass, fused silica glass, borax glass, transparent mirror glass, and the like.
  • glass compositions such as borosilicate glass, aluminosilicate glass, Vicor glass, fused silica glass, borax glass, transparent mirror glass, and the like.
  • the glass charged via line 14 contains from at least about 50 to about 75 weight percent of silica in the glass.
  • silica sand is charged to mixer 10 via line 16; in a more preferred embodiment, from about 10 to about 25 weight percent of silica sand is so charged.
  • This silica sand preferably has a particle size distribution such that at least about 70 percent of its particles range in size from about 0.05 to about 2.0 millimeters.
  • a sufficient amount of glass and/or silica sand and/or silica-containing material is added so that the final composition contains about 30 to 55 weight percent of silica.
  • Silica sand is well known to those skilled in the art and is described, e.g., in U.S. Pat. Nos. 5,613,453, 5,551,632, 5,492,548, 5,476,416, 5,472,500, 5,426,145, 5,411,352, 5,334,364, 4,401,638, 3,856,213, and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • glass flux material may be charged to mixer 10 via line 18.
  • a flux is a substance added to a refractory material to aid in its melting.
  • One preferred glass flux is sodium oxide, or a precursor material (such as sodium carbonate) which, upon heating, yields sodium oxide. It will be appreciate, when referring to any oxide materials herein, that one also may use precursor materials (such as, e.g., metal carbonates) which are transformed into the oxide by heating.
  • Another preferred glass flux is calcium oxide, or its precursor.
  • Yet another preferred glass flux is magnesium oxide, or its precursor. Barium oxide and/or strontium oxide, and/or their precursors, also may be used as a fluxing agent.
  • reagents also may be added to the glass batch in mixer 10.
  • at least about 70 percent of the alumina particles charged are preferably smaller than 10 microns.
  • Furnace 22 preferably has an elongated shape and is equipped with a multi-zone temperature control.
  • the furnace has a low velocity exhaust.
  • Furnaces with low velocity exhaust are well known to those skilled in the art; see, e.g., U.S. Pat. No. 4,410,996, the entire disclosure of which is hereby incorporated by reference into this specification.
  • furnace 22 it is preferred, within furnace 22, to maintain the glass melt at a substantially constant shallow depth of from about 6 to about 12 inches; this is done to insure substantially that the same temperature will be found throughout the depth of the melt.
  • Means for maintaining a melt at a shallow depth are well known to those skilled in the art and are described, e.g., in U.S. Pat. Nos. 4,289,571, 4,157,728, 4,002,468, 3,875,322, 3,801,309, and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • furnace 22 is preferably equipped with at least three heating zones, viz., heating zones 14, 26, and 28. In another embodiment, not shown, a furnace with only one melting zone is used.
  • heating zone 24 is used as a preheating zone.
  • the furnace temperature is maintained at from about 1,500 to about 2,400 degrees Fahrenheit; a sensor, such as sensor 25, preferably monitors the temperature within the glass batch.
  • the glass batch is maintained in this zone until substantially all of it is has reached the desired temperature of from about 1,500 to about 2,400 degrees Fahrenheit.
  • the preheated glass batch is then subjected to a temperature of from about 2,300 to about 2,800 degrees Fahrenheit in melting zone 26; a sensor, such as sensor 27, monitors the temperature and the viscosity of the glass melt and determines when, in fact, it has been completely melted.
  • the "soak time" during which the preheated glass batch is in the melting zone 26 preferably is from about 3 to about 5 hours, depending upon the size of the batch;, and, more preferably, it is from about 3.5 to about 4.5 hours.
  • gases form which may include hazardous substances incorporated therein in liquid, vapor, or particulate form.
  • gases such as chlorine, fluorine, sulfur dioxide, mercury vapor, lead vapor, cadmium vapor, and the like, may be evolved.
  • the off gases produced during the melting process are preferably passed via line 30 to scrubber 31, which is adapted to remove hazardous particulate liquid and vapor byproducts from the gas entering the scrubber.
  • scrubber 31 is adapted to remove hazardous particulate liquid and vapor byproducts from the gas entering the scrubber.
  • Such exhaust gas scrubbers are well known and are described, e.g., in U.S. Pat. Nos. 5,627,682 (scrubber for waste gas), 5,593,469 (exhaust gas scrubber), 5,540,760, 5,512,097, 5,505,752, 5,415,684, 5,009,511, and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • the glass melt after the glass melt has been maintained in the melting zone 26 for the desired time, it is then preferably passed to refining zone 28.
  • the glass melt In this refining zone, the glass melt is preferably maintained in a substantially motionless state at a flow rate of less than about one inch per minute while being subjected to a temperature of from about 2,400 to about 2,900 degrees Fahrenheit.
  • a sensor 29 is maintained in the glass melt to monitor the temperature and viscosity within the glass melt.
  • controller which, via feedback line 34, is adapted to maintain the desired temperatures in zones 24, 26, and 28.
  • the refining zone 28 is omitted, and the molten glass from melting zone 26 is directly quenched.
  • the partially crystallized melt from refining zone 28 is withdrawn and quenched by preferably being contacted with water 42. It is preferred, when quenching the glass melt from furnace segment 28, that the temperature of the glass melt be reduced from its initial temperature (of from about 2,400 to about 2,900 degrees Fahrenheit) by at least about 1,000 degrees Fahrenheit in less than about 5 seconds. Thus, by way of illustration and not limitation, one may withdraw molten glass from furnace segment 28 into a molten glass stream 40 and blast one or more streams 42 of water against the molten flow 40 at a high pressure of from about 40 to about 60 pounds per square inch. In this embodiment, it is preferred to have the source of the water (not shown) be disposed at from about 10 to about 18 inches from the molten glass stream 40. In this process, following such high pressure quenching, the quenched material drops into a quenching bath of hot or boiling water 44.
  • the disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • the quenched glass is then crushed or broken by suitable means, such as a hammer or ball mill, to form grits or particles.
  • suitable means such as a hammer or ball mill
  • Any method for comminuting the solid can be used, and the term "crushing" is used to include all such methods.
  • crushing is used to include all such methods.
  • the quenched glass is moved via an auger 46 in bath 44 and passed via lines 48 to grinder 50, in which the size of the quenched glass material is reduced so that substantially all of the glass particles have a largest dimension less than about 5 millimeters. It will be appreciated that the grinding can be conducted to produce other particle size distributions, both larger and smaller.
  • the glass is comminuted so that the particles pass through a 20 mesh sieve (841 microns) but are retained on a 40 mesh sieve (420 microns); this is referred to as a 20/40 compact.
  • the glass is crushed so that the particles pass through an 80 mesh screen (177 microns) but are retained on a 120 mesh screen (125 microns); this is referred to as an 80/120 compact.
  • the glass is crushed so that the particles pass through a 20 mesh screen (841 microns) but are retained on a 30 mesh screen (595) microns; this is referred to as a 20/30 compact.
  • the glass is crushed so that the particles pass through a 40 mesh screen (420 microns) but are retained on a 60 mesh screen (250 microns); this is a 40/60 compact.
  • the glass is crushed so that the particles pass through a 120 mesh screen (125 microns) but are retained on a 200 mesh screen (74 microns); this is a 120/200 compact
  • the ground glass may then be passed via line 52 to siever 54, in which the desired particle sizes are produced for the final product.
  • classifying means besides sieving may be used to classify the crushed material.
  • the disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • the ground material from grinder 50 is first passed via line 51 to heat treater 53. Applicant has found, unexpectedly, that heat treatment at this stage of the process substantially improves the properties of the finished product.
  • heat treater 53 it is preferred to subject the ground material to a temperature of from about 740 to about 760 degrees Centigrade for about 2.5 to about 3.5 hours.
  • the material is first raised from ambient temperature to the soak temperature of 740-760 degrees Centigrade over a period of from about 3.5 to about 4.5 hours, held at the soak temperature for from about 2.5 to about 3.5 hours, and then cooled over a period of at least 7 hours.
  • the furnace used for heat treater 53 is a 30 square foot shuttle furnace manufactured by the Frederick Kiln Company of Alfred Station, New York.
  • This furnace contains an orifice metering system, a multiple burner flame supervisory system, valve actuators, gas regulators, and a turboblower, all of which are manufactured by the North American Inc. Manufacturing Company of 4455 East 71 st Street, Cleveland, Ohio.
  • the furnace is also equipped with a Yokogawa Electric Program Controller, Model UP25, and a primary control manufactured by the Honeywell Corporation.
  • the furnace also contains an ultraviolet flame detector manufactured by Honeywell.
  • the heat treated material from heat treater 53 is preferably passed via line 55 to siever 54.
  • the sieved material from siever 54 is passed via line 56 to bagger 58, wherein the sieved particles are bagged.
  • the composition of this invention can be used as roofing granules.
  • the particle sizes of the granules range from about 0.2 to about 2.0 millimeters.
  • the roofing granules of this invention may replace prior roofing granules in such structures as those disclosed, e.g., in U.S. Pat. Nos. 5,516,573 (roofing granules embedded in asphalt), 5,382,449, 4,380,552, 5,206,068, and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
  • the composition of this invention can be used as a proppant; it can be suspended in drilling fluid during the fracturing portion of the drilling operation to keep the fracture open when fluid is withdrawn.
  • such composition may be used as a proppant in one or more of the applications disclosed in U.S. Pat. Nos. 5,620,049, 5,604,194, 5,597,043, 5,595,245, 5,582,250, 5,575,335, 5,562,160, 5,558,161, 5,531,274, 5,515,920, and the like.
  • the particle size of the proppant particles used is from about 0.2 to about 3.0 millimeters.
  • the composition of this invention can be used to manufacture foam glass.
  • foam glass is a light, black, opaque cellular glass made by adding powdered carbon to crushed glass and firing the mixture.
  • foam glass is a light, black, opaque cellular glass made by adding powdered carbon to crushed glass and firing the mixture.
  • the composition of this patent is used to make foam glass structural elements or foam glass panels, such as those described in U.S. Pat. Nos. 4,024,309, 5,464,114, 4,557,090, 4,463,043, 3,628,937, and the like.
  • the disclosure of each of these United States patents is hereby incorporated by reference into this specification. It is to be understood that the aforementioned description is illustrative only and that changes can be made in the apparatus, in the ingredients and their proportions, and in the sequence of combinations and process steps, as well as in other aspects of the invention discussed herein, without departing from the scope of the invention as defined in the following claims.

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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6057257A (en) * 1998-07-28 2000-05-02 Howard J. Greenwald Abrasive composition
WO2001042154A1 (fr) * 1999-12-06 2001-06-14 Rgs90 Procede de fabrication de verre et verre produit selon ce procede
US6524682B1 (en) 2000-11-01 2003-02-25 Owens-Corning Fiberglas Technology, Inc. Glass backdust for roof covering
KR100683834B1 (ko) 2005-12-30 2007-02-15 경기대학교 산학협력단 전기로 제강분진을 이용한 결정화유리 제조방법
US20070231541A1 (en) * 2006-03-31 2007-10-04 3M Innovative Properties Company Microstructured tool and method of making same using laser ablation
US20070235902A1 (en) * 2006-03-31 2007-10-11 3M Innovative Properties Company Microstructured tool and method of making same using laser ablation
US7648933B2 (en) 2006-01-13 2010-01-19 Dynamic Abrasives Llc Composition comprising spinel crystals, glass, and calcium iron silicate
US20100068521A1 (en) * 2008-09-17 2010-03-18 The Penn State Research Foundation Treatment of melt quenched aluminosilicate glass spheres for application as proppants via devitrification processes
US20100162757A1 (en) * 2007-01-12 2010-07-01 Brodie Sally H Novel process
US20130097942A1 (en) * 2010-06-22 2013-04-25 James Morano Converting Coal Ash and Electric Arc Furnace Dust Into Glass-Ceramic Materials
US8959954B2 (en) 2008-09-17 2015-02-24 The Penn State Research Foundation Proppants from mineralogical material
IT201800005627A1 (it) * 2018-05-23 2019-11-23 Procedimento per ottenere materiali abrasivi da aggregati inerti derivanti da scorie metallurgiche
CN113698076A (zh) * 2021-09-02 2021-11-26 江苏圣君纳米科技有限公司 一种异型石英玻璃的生产方法

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US6057257A (en) * 1998-07-28 2000-05-02 Howard J. Greenwald Abrasive composition
WO2001042154A1 (fr) * 1999-12-06 2001-06-14 Rgs90 Procede de fabrication de verre et verre produit selon ce procede
AU776548B2 (en) * 1999-12-06 2004-09-16 Rgs90 Method for producing a glass and glass produced thereby
US7017371B2 (en) 1999-12-06 2006-03-28 Rgs90 Method for producing a glass
KR100731401B1 (ko) * 1999-12-06 2007-06-21 알지에스90 유리를 제조하는 방법 및 이에 의해 제조된 유리
US6524682B1 (en) 2000-11-01 2003-02-25 Owens-Corning Fiberglas Technology, Inc. Glass backdust for roof covering
KR100683834B1 (ko) 2005-12-30 2007-02-15 경기대학교 산학협력단 전기로 제강분진을 이용한 결정화유리 제조방법
WO2007078120A1 (fr) * 2005-12-30 2007-07-12 Kyonggi University Industry & Academia Cooperation Foundation Procede de fabrication de vitroceramique au moyen de limaille d'acier dans un four
US20100037657A1 (en) * 2005-12-30 2010-02-18 Kyonggi University Industry & Academia Cooperation Foundation Manufacturing method of glass-ceramics using steel dust in furnace
US7648933B2 (en) 2006-01-13 2010-01-19 Dynamic Abrasives Llc Composition comprising spinel crystals, glass, and calcium iron silicate
US20070235902A1 (en) * 2006-03-31 2007-10-11 3M Innovative Properties Company Microstructured tool and method of making same using laser ablation
US20070231541A1 (en) * 2006-03-31 2007-10-04 3M Innovative Properties Company Microstructured tool and method of making same using laser ablation
US20100162757A1 (en) * 2007-01-12 2010-07-01 Brodie Sally H Novel process
US20100068521A1 (en) * 2008-09-17 2010-03-18 The Penn State Research Foundation Treatment of melt quenched aluminosilicate glass spheres for application as proppants via devitrification processes
US8359886B2 (en) * 2008-09-17 2013-01-29 The Penn State Research Foundation Treatment of melt quenched aluminosilicate glass spheres for application as proppants via devitrification processes
US8959954B2 (en) 2008-09-17 2015-02-24 The Penn State Research Foundation Proppants from mineralogical material
US20130097942A1 (en) * 2010-06-22 2013-04-25 James Morano Converting Coal Ash and Electric Arc Furnace Dust Into Glass-Ceramic Materials
US8603240B2 (en) * 2010-06-22 2013-12-10 James Morano Converting coal ash and electric arc furnace dust into glass-ceramic materials
IT201800005627A1 (it) * 2018-05-23 2019-11-23 Procedimento per ottenere materiali abrasivi da aggregati inerti derivanti da scorie metallurgiche
CN113698076A (zh) * 2021-09-02 2021-11-26 江苏圣君纳米科技有限公司 一种异型石英玻璃的生产方法
CN113698076B (zh) * 2021-09-02 2022-05-27 江苏圣君纳米科技有限公司 一种异型石英玻璃的生产方法

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